PDF Maintenance Manual Raymond 8300 8400 8500 Pallet Trucks & 8600 Tow Tractor - 2 MB
This is the official maintenance manual for the Raymond 8000 series, including the 8300, 8400, and 8500 Pallet Trucks, as well as the 8600 Tow Tractor.
It covers models with serial numbers from 59749 to 83000.
The manual provides detailed procedures for scheduled maintenance, adjustments, and troubleshooting.
Following these guidelines is essential for keeping your warehouse fleet in excellent working condition and ensuring operator safety.
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--- Page 1 ---
Maintenance Manual
Models 8300, 8400, and 8500 Pallet Trucks
and Model 8600 Tow Tractor
Models: Serial Numbers:
8300, 8400, 8500, and 8600 59,749 to 83,000
Publication: 1034066E Revised: 18 Dec 2009
Replaces
Publication: 1034066D Revised: 15 May 2009
--- Page 3 ---
Raymond ® Pallet Truck Maintenance Manual Section 1. How To Use This Manual
Page Revision Record
Page Revision Record
Section 1. How To Use This Manual
This page is a record of the revision of all pages
in this manual. Whenever a page is revised, this
section is updated and included in the revision.
Pages are revised due to technical and
non-technical changes identified as follows:
• Technical changes – These changes are
identified by a vertical line (change bar) in
the left margin next to the change. Pages
affected by technical changes are
identified with “Revised: Month Year” in
the footer. These pages may also be
available on the Raymond iNet.
• Non-technical changes – These changes
consist of typographical and grammatical
corrections, paragraph renumbering,
repagination, and so on. Non-technical
changes are not identified with a change
bar, however, affected pages are identified
with “Revised: Month Year” in the footer.
Document Revision History
• 1034066A, Original Issue Date,
Issued: 11 November 2005
• 1034066B, Revision B,
Revised: 3/17/06
• 1034066C, Revision C
Revised: 11/26/07
• 1034066D, Revision D
Revised: 05/15/09
• 1034066E, Revision E
Revised: 18 Dec 2009
List of Revised Pages
Revision E standardized placement of content
into eight chapters instead of six. Chapters
were added for Messages and Codes and Theory
of Operation, removing this content from the
Troubleshooting chapter. Operator Display and
Programming content was moved from the
Troubleshooting chapter to the Systems
Overview chapter. These changes align content
of this manual with other Raymond manuals to
aid users in locating information from one class
truck to another.
Publication: 1034066, Revised: 18 Dec 2009 ix
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Raymond ® Pallet Truck Maintenance Manual Section 1. How To Use This Manual
START Page
Start2.wmf
START: 2
Go to Chapter 5.
Troubleshoot a problem? Yes Troubleshooting
No
Go to Chapter 6.
Troubleshoot a fault Messages and
code or run a diagnostic Yes
Codes
test?
No
Go to Chapter 7.
Test, inspect, adjust, Component
remove/install a Yes
Procedures
component?
Component
Procedures List by
No System
Go to
Chart Component Locator
Start: 3. Photographs
Publication: 1034066, Revised: 18 Dec 2009 1-7
--- Page 5 ---
Raymond ® Pallet Truck Maintenance Manual Section 2. Safety
Tie-Down for Transport
Tie-Down for Transport
To transport your Raymond pallet truck in an
over-the-road vehicle or rail car, perform these
steps:
1. Lower the forks and put the truck in the
center of the transport vehicle.
2. Using suitable lifting device, remove the
battery. See “Battery” on page 7-46.
3. Position the adjustable chain over and
thru the battery compartment.
4. Position an additional adjustable chain
over and thru the battery compartment.
5. Position the chain ends of one chain
toward the front of the vehicle bed and the
chain ends of the other chain to the back
of the vehicle bed and draw taut. See
Figure 2-1.
Figure 2-1. Tie-Down for Transport
2M-1.tif
NOTE: This secures the truck to the vehicle bed
and prevents tip-over and forward or
backward movement.
6. Secure the battery according to the battery
manufacturer’s instructions. If equipped,
remove the battery cover or storage tray
from the top of the battery and store
separately.
Publication: 1034066, Revised: 18 Dec 2009 2-9
--- Page 6 ---
Raymond ® Pallet Truck Maintenance Manual Section 3. Systems Overview
Operator Display and Programming
• When the handle is released at a 2. Release the horn button when the “P” is
chosen history number (1-50), the displayed. The parameter control indicator
display first shows the caution or error is illuminated. See Figure 3-8.
code and then the activity hour (Hour 3. Use the directional/speed control to scroll
meter B) the fault occurred. to the desired truck parameter you want to
• For example, if you only have one fault change or view. See Table 3-1. Release the
registered in the memory, the second directional/speed control to neutral when
empty position is shown like this: Fault: the desired parameter number and value
E - - - and time: - - - -. is displayed.
3. Turn the truck OFF to end displaying the NOTE: All parameters can be viewed; however,
error code history. not all parameters can be changed.
Individual operator parameters (1 thru
Changing Truck Parameters (P) 7) may or may not be accessed,
depending on the value of service
parameter 39.
4. Press the horn button once. The
parameter control indicator on the display
Modifying specific truck parameters starts flashing.
changes the driving characteristics of the
truck. 5. Change the parameter value by rotating
the directional/speed control up or down.
NOTE: Parameters 1 thru 7 are individual Release the directional/speed control to
operator (driver) parameters. Parameters neutral when the desired parameter
10 thru 40 are service parameters. number is shown.
Individual operator parameters 6. Press the horn button again to confirm the
(1 thru 7) may or may not be accessed, change. The parameter control indicator
depending on the value of service on the display stops flashing and remains
parameter 39. See Table 3-2, “Service illuminated.
Parameters,” on page 3-9. 7. Turn the truck OFF to end programming.
Programming Operator Parameters The truck parameter change is complete. The
next time the truck is started, the new
To program the trucks operator parameters parameter is in effect.
follow directions below:
Table 3-1. Truck (Operator) Parameters
1. Enter special truck mode. See “Special
Truck Mode” on page 3-6.
Range
Parameter Name Model Default Description
(Step)
01 Max Speed, 8300, 0 to 42% 42% Maximum requested speed in walking
Walking 8400, (2%) speed mode (coast engaged mode on
Speed Mode 8500, models 8400 and 8500). This parameter
and 8600 controls the scaling of the throttle request.
02 Max Speed, 8400, 0 to 100% 100% Maximum requested speed when in Rabbit
Rabbit Mode 8500, (2%) mode. This parameter controls the scaling
and 8600 of the throttle request.
03 Acceleration 8400, 1 to 5 2 Selects from a table for acceleration rate.
Rate for 8500, (1) (3 - 1= fastest,
Riding Speed and 8600 10.5 in. 5 = gentlest.
Mode Dia. Tire)
Publication: 1034066, Revised: 18 Dec 2009 3-7
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Raymond ® Pallet Truck Maintenance Manual Section 3. Systems Overview
FlashWare
Configuration and Truck Setup
Options
The Truck Setup screen feature allows you to:
• View and change options (parameters)
• View and change the serial number, model
number, software model number, and
hour meters of the truck (with a passkey).
See Figure 3-12.
Figure 3-12. Typical Truck Setup Screen
3Image7.jpg
Changing Truck Parameters: The Truck Parameters area lists the truck
options.
Options and hour meters displayed in red 1. Scroll to the parameter that you would like
require authorization codes. When these to change and click the value field.
options are selected, a pop up window appears
requesting the authorization code. Contact your 2. Enter the corresponding number that
local Raymond dealer for the correct forms and matches how you want the truck set. See
procedure for obtaining the authorization Figure 3-13.
codes. Authorization codes are available that
allow you to change the Serial Number, Hour
Meters, and Date of Manufacture.
Publication: 1034066, Revised: 18 Dec 2009 3-17
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Raymond ® Pallet Truck Maintenance Manual Section 4. Scheduled Maintenance
Every 180 Days or 500 Deadman Hours
Perform the following maintenance tasks every 180 days or 500 HD, whichever comes first.
Component Task
Frame and Tractor General visual inspection of structural members for cracks, including but not limited
Checks to the fork frame and tractor.
Hardware Check bolt torque of major components (motors, brake, drive unit). Tighten any loose
hardware. Replace any broken or missing hardware. See “Component Specific
Service/Torque Chart” on page A-4.
Horn Check that the horn operates when you press the horn button.
Hydraulic Hoses Inspect all hydraulic hoses for leaks, nicks, cut, chafing, and bulges. Replace
damaged hoses as soon as possible. Inspect all fittings for leaks. Repair any leaks
immediately.
Hydraulic Reservoir Check fluid level. See “Hydraulic Fluid” on page 7-83.
Lubrication Lubricate all grease points and control handle pivot points. Lowest SM interval for
truck. See “Grease Fittings (All Models)” on page 4-8.
Motors AC - Check the cable lugs to make sure they are tight to the terminal studs. Torque
the outside nut to the values listed. Replace any cable that shows signs of excessive
heat. Check sensor wires for sound connection and condition. Blow out the inside of
the motor with compressed air.
DC - Check condition of brushes, springs, and holders. Check that the brush length
exceeds the minimum length. Hydraulic Pump motor: 1/2 in. (13 mm). Inspect the
commutator. See “Inspection” on page 5-12. Blow out the inside of the motor with
compressed air. See “Lift Motor” on page 7-79.
Pallet Entry Check and replace damaged wheels/sliders as necessary. See “Pallet Entry Sliders”
Wheels/Sliders on page 7-107.
Traction Amplifiers Torque power cable terminal nuts to 100 in. lb. (11.3 Nm).
Shorts to Frame Check for electrical shorts to frame. See “Shorts to Frame Test” on page 5-8. Wipe
down the inside of the compartment.
Static Straps Make sure static straps are not worn or broken. Clean debris from straps.
Switches Check all switches for correct operation and adjust as needed.
Warning Decals Replace any unreadable or damaged decals.
Load Wheels and Examine for bond failure, chunking, and excessive or uneven wear. Inspect load
Drive Tires wheel bearings for binding or excessive play.
Publication: 1034066, Revised: 18 Dec 2009 4-5
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Raymond ® Pallet Truck Maintenance Manual Section 5. Troubleshooting
Troubleshooting Flowcharts
END1: End of Troubleshooting
Procedure
Figure 5-3. END1: End of Troubleshooting Procedure
5End1.wmf
END1: End of Troubleshooting Procedure
Make sure ALL wires, hoses,
Have the driver operate the
and cables that you
lift truck. make sure the
removed have been
problem does not recur.
reattached correctly.
Test all other truck
Make sure all panels are
functions before returning
correctly reinstalled.
the lift truck to service.
Make sure any component
that was drained has been
Fill out any required forms.
refilled with the correct level
of fluid.
If you are a Raymond dealer
This is especially
Create the same conditions technician and contacted
important if the
that occurred when the Raymond Field Service to
solution you found
problem first happened. discuss the problem, call
is not in the
them again to let them
troubleshooting
know what fixed the
chart.
problem.
Operate the truck as it was
being operated when the
problem occurred. Make End of Troubleshooting
sure the problem does not
recur.
Publication: 1034066, Revised: 18 Dec 2009 5-5
--- Page 10 ---
Raymond ® Pallet Truck Maintenance Manual Section 5. Troubleshooting
DC Electric Motor Tests
Grounded Motor Test Short-Circuited Winding
In a grounded motor, an electrical circuit exists A short-circuited winding is one where the
between the current-carrying conductors and insulation on the field or armature has broken
the motor housing. This can be caused either by down at two or more points. The breakdown
direct contact or thru conductive foreign creates a low resistance path, permitting
material. current to flow from one turn of the coil to
another adjacent coil turn, without actually
The ground may be caused by: flowing thru the coil wire. The result is a
• Insulation breakdown decrease in total resistance of the motor
winding and an increase in the current flow.
• Brush leads touching the motor housing The severity of the short circuit depends on its
• Build-up of carbon dust or other materials location.
To test a motor for grounds: A shorted motor may be indicated by:
1. Isolate the motor from the truck circuit by • Slow or sluggish operation
removing the power cables. Use two • Running faster than normal
wrenches to avoid twisting the terminal
studs. • Overheating
2. Attach one lead of a megohm meter or a • Blowing a power fuse
digital ohmmeter to a motor terminal and • On DC motors, severe burning or
the other lead to an unpainted surface of discoloring on one or two commutator
the motor housing. Set the ohmmeter to segments every 90° of rotation
the highest scale.
3. If the ohmmeter reads resistance of less These symptoms can be caused by problems
than 100,000 ohms, the motor is other than the motor itself:
grounded. Clean, repair, or replace the • Brake too tight or dragging
motor as necessary. • Wheel bearings too tight
• Faulty transmission
Short-Circuited Armature • Binding in an attached pump
A short circuit in the armature causes heating
Testing a motor for short-circuited windings
that could result in burning of:
requires special equipment at a motor
• Armature coil rebuilding facility.
• Brush wires
• Commutator segments
Visual inspection may reveal this condition.
Positive determination of a short-circuited
armature requires special equipment at a motor
rebuilding facility.
Publication: 1034066, Revised: 18 Dec 2009 5-15
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Raymond ® Pallet Truck Maintenance Manual Section 5. Troubleshooting
Symptom Tables: Travel (Forward/Reverse) System
Table 5-19. No Rabbit Speed, Travel/Lift/Lower OK. No Fault Codes
Possible Cause Action
NOTE: Rabbit speed only works in the NOTE: Rabbit speed (actual) is dependant on:
tractor -first (forward) direction.
1. +12V present at JP1-9 (Rabbit Input 3) of TA
End rider models are equipped with
“latched” rabbit speed buttons. Press 2. CAN Hi input Comm I/O signal at JP1-23
and release the button to enable 3. Traction motor armature current
rabbit speed. Rabbit speed is disabled
by applying brake or returning the
throttle to neutral.
Traction Amplifier programming changed Jack and block truck. Verify programming. If changed,
reset programming. See “Changing Truck Parameters (P)”
on page 3-7. Verify inputs of B+ at TA and VM.
Bad control handle switches or grab rail For control handle switches, enter the digital input test for
switches rabbit switches and verify operation. For the grab rail
switch, measure voltage at JP1-14 wrt B–. With the switch
closed, voltage should be between 10.5 and 13 volts. With
switch open, voltage should be 0 volts. If okay, replace the
TA.
Table 5-20. No Truck Functions Active. TA Flash Code 1,8, (Excessive Battery Voltage). Operator
Display May Indicate E222
Possible Cause Action
Battery Problem Verify the correct, (24V) fully-charged, battery is installed
in truck.
Is battery charger plugged into truck? Disconnect battery charger immediately.
Bad Traction Amplifier Verify battery voltage at key switch input. Measure voltage
at JP1-1 wire with JP1 disconnected. If 24V, replace TA.
Publication: 1034066, Revised: 18 Dec 2009 5-25
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Raymond ® Pallet Truck Maintenance Manual Section 6. Messages and Codes
Traction Amplifier Flash Codes
TA
Error
Flash Description Action
Code
Code
5,1 E150 Initial CAN Message Not Recieved See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,1 E150 CAN Timeout Error See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,3 E150 Ead SDO CAN Message See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,5 E150 Ead Communication Spec See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
6,8 E232 VCL Runtime See “Code E232” on page 6-26.
6,9 E230 External Supply Out-of-Range See “Code E230” on page 6-25.
7,1 CAN Timeout, No Truck Functions Active See Table 5-32 on page 5-29.
7,2 E150 FDO CAN Message Timeout See “Troubleshooting the CAN Bus”
or on page 5-6.
blank
7,3 C72 Traction Motor Stalled See “Code C72” on page 6-18.
Publication: 1034066, Revised: 18 Dec 2009 6-5
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Raymond ® Pallet Truck Maintenance Manual Section 6. Messages and Codes
Caution Codes
Table 6-59. Code C50
Code Title Lift Switch Active on Power Up
Operator Display C50
System Response Traction performance limited. LOS (Limited Operating Strategy)
Outputs available Main, Horn, and Lower
Alarm Sounds No
Reason Grab Rail/Load Backrest Lift switch (SW15) active on power up, or pin 12 on TA
shorted to B+. TA inputs to JP1-12 are ON
Tests to Run Examine VM, Traction Amplifier, and related wiring
How to Clear Clear input (held switch, stuck switch, or shorted lead). Cycle key switch OFF/ON.
Table 6-60. Code C51
Code Title Lower Switch Active on Power Up
Operator Display C51
System Response Traction performance limited. LOS (Limited Operating Strategy)
Alarm Sounds No
Reason Grab Rail/Load Backrest Lower switch active on power up or pin 11 on TA shorted
to B+. TA inputs to JP1-11 are ON
Tests to Run Examine VM, Traction Amplifier, and related wiring
How to Clear Clear input (held switch, stuck switch, or shorted lead). Cycle key switch OFF/ON.
Table 6-61. Code C52
Code Title Grab Rail/Load Backrest Lift/Lower Switches Active at Same Time
Operator Display C52
System Response Traction performance limited. LOS (Limited Operating Strategy)
Alarm Sounds No
Reason Grab Rail/Load Backrest Lift and Lower switches active on power up, or pin 11 and
12 on TA shorted to B+. TA inputs to JP1-11 or JP1-12 are ON
Tests to Run Examine VM, Traction Amplifier, and related wiring
How to Clear Clear inputs (held switches, stuck switches, or shorted leads). Cycle key switch
OFF/ON.
Publication: 1034066, Revised: 18 Dec 2009 6-15
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Raymond ® Pallet Truck Maintenance Manual Section 6. Messages and Codes
Error Codes
Table 6-89. Code E225
Code Title Precharge Fault
Operator Display E225
TA Flash Code “1,4”
System Response No truck function active
Alarm Sounds No
Reason TA precharge circuit failed
Tests to Run None
How to Clear Try cycling key switch OFF/ON. If that does not solve the problem, replace TA.
Table 6-90. Code E228
Code Title Parameter Change Fault
Operator Display E228
TA Flash Code “4,9”
System Response No truck function active
Alarm Sounds No
Reason TA parameters have changed. Critical TA parameter changed while operating
Tests to Run None
How to Clear Cycle key switch OFF/ON.
Table 6-91. Code E230
Code Title External Supply Out-Of-Range
Operator Display E230
TA Flash Code “6,9”
System Response No truck function active
Alarm Sounds No
Reason External supply current out-of-range (+12V, +5V). Devices connected to these
outputs on the TA are drawing too much current (> 250 mA)
Tests to Run If not cleared by cycling key switch OFF/ON, try to determine what device caused
the problem
How to Clear Cycle key switch OFF/ON.
Publication: 1034066, Revised: 18 Dec 2009 6-25
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Raymond ® Pallet Truck Maintenance Manual Section 7. Component Procedures
Component Locator Photos
Figure 7-3. Model 8400 (Long-John Forks Shown)
7ray100a.jpg
Control Grab Rail
Handle
Battery
Tractor Fork Section
Cover
Load Wheels
Caster
Wheel
Publication: 1034066, Revised: 18 Dec 2009 7-7
--- Page 16 ---
Raymond ® Pallet Truck Maintenance Manual Section 7. Component Procedures
Steering and Controls Control Handle
Control Handle
Figure 7-12. Handle and Control Head Assembly
W1027306_C1.cgm,W1027306_C2. cgm
Pos Description
1 Screw
2 Washer, Nylon
5 Grip, Handle
19 6 Lower Control Housing
7 Handle Arm Assembly
20
15 15 Stem Harness
30
16 Control Head Assembly
17
17 Screw
18 Screw
18
19 Screw
6 20 Cover, Hood
30 Keypad (Optional)
7
Control Head
16 Assembly
See Figure 7-13.
5
Detail View - Bottom
1
2
Detail View -
Top
Publication: 1034066, Revised: 18 Dec 2009 7-17
--- Page 17 ---
Raymond ® Pallet Truck Maintenance Manual Section 7. Component Procedures
Drive and Brake Drive Unit
Figure 7-27. Lower Drive Unit, Cross-Sectional View
W1031913_A.cgm
LEGEND: 26
1. Spiral Gear 19. Shim
and Pinion Set 20. Shim 11
2. Bearing Set 21. Shim 23
3. Bearing Set 23. Clamp Nut
4. Bearing Set 24. Clamp Nut 27
5. Bearing Set 25. Gear Axle
6. Oil Seal 26. Pinion
7. Magnetic Plug Helical Gear 29
10. Screw 27. Helical Gear
11. Nut 28. Lower Gear
12. Cover Plate Housing 33
13. Spacer 29. Upper Gear 31
14. Shim Housing
15. Shim 30. Steering 30
16. Shim Bearing Assy.
17. Shim 31. O-Ring Seal
13
18. Shim 32. Screw 12
33. Set Screw 5
3
14 10
15
16